Method and device for producing a mold

ABSTRACT

Device and method for the production of a mold having a fiber-reinforced support and connected therewith at least one add-on piece featuring synthetic material, with the device having at least one first tool component ( 10 ) and a second tool component ( 20 ), at least one of which is movable relative to the other; in this way, the device can be opened to insert a fiber-reinforced mat ( 30 ) between the respective pressing surfaces ( 11, 21 ) of the two tool components ( 10, 20 ), and closed for pressurizing and molding the mat ( 30 ), which produces the fiber-reinforced support, and with the second tool component ( 20 ) having at least one nozzle ( 22 ) to supply a liquefied synthetic material, and the first tool component ( 10 ) having at least one cavity ( 12 ) away from the nozzle to form the add-on piece, characterized in that the second tool component ( 20 ) has at least one cavity ( 24 ) at the nozzle so that the add-on piece can be produced and integrated by introducing synthetic material through the nozzle ( 22 ) and through the mat ( 30 ) into the cavity ( 12 ) away from the nozzle and the cavity ( 24 ) at the nozzle and hardening it therein.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims the benefit of prior GermanApplication No. 10 2013 016 858.9, filed on Oct. 10, 2013, the entirecontents of which are incorporated herein by reference.

TECHNICAL FIELD

The disclosure relates to a device and a method for the production of amold with a fiber-reinforced support and connected therewith at leastone add-on piece featuring synthetic material, with the mold beingsuitable in particular for use as a decorative part or furtherprocessing in the interior of motor vehicles.

BACKGROUND OF THE DISCLOSURE

Until now, supports for decorative parts, such as for interior doorpanels, center door panels, center consoles, instrument panels and thelike were produced in injection molding processes or by means ofpressing thermal or duroplastic natural fiber mat systems. Theconnection between the function elements such as stiffening ribs,fastening means, and the like is normally achieved by gluing on orwelding on the synthetic parts. These supports are then laminated withdecorations. Another production method is the direct in-mold decorating.

If molded support parts are used, the process steps of molding thesupport mat and injecting the function elements and connecting thefunction elements to the molded support are generally performed indifferent process steps and with different tools.

DE 10 2004 054 228 A1 describes a method and a device for the productionof a mold, with a natural fiber blank being heated in a first step, andthen a mold being produced from the blank by pressing two form elementstogether. Thereafter, a function part is molded onto the mold byinjecting a synthetic material melt, with a cavity being created at themold prior to injecting the synthetic material melt. These steps areperformed in one device. A similar method and a similar device aredescribed in DE 692 22 130 T2.

In both cases, the function elements or synthetic material parts areinjection-molded to the natural fiber mat. An improved integrationbetween the pressed mat and the function parts requires additionalprocess steps and additional devices.

An improvement of the integration between natural fiber mat and functionelements is described in DE 10 2011 005 350 A1. The device in DE 10 2011005 350 A1 has two tool components that are movable relative to oneanother. When the tool components are in an opened state, afiber-reinforced mat can be inserted, which is molded and strengthenedby means of pressure during closing. A nozzle is provided in one of thetwo tool components, through which liquid synthetic material is pressedonto the inserted mat in such a fashion that the synthetic material meltpenetrates the inserted mat and reaches a cavity on the opposite side,which is developed in the other tool component.

What is problematic is attaching function elements on the nozzle side ofthe fiber-reinforced mat and on both sides of the mat. In addition,there is a general desire for an even better and more durable connectionbetween the add-on elements and the mat.

SUMMARY

One object of the disclosed embodiments is to improve the integrationbetween a pressed, fiber-reinforced support and add-on pieces featuringsynthetic material for the production of a mold, in particularfacilitating a two-sided development of one or more add-on pieces underoptimized production processes.

The object is achieved with a device (also referred to as a “tool”)having the characteristics consistent with embodiments of thedisclosure.

The tool according to the disclosure combines the properties of apressing tool and an injection-molding tool. The production of a supportfora decorative part, for example a support for the interior door panelwith a thermal- or duroplastic fiber-reinforced mat as base support, andadd-on pieces provided at both sides, such as function elements,stiffening elements, etc., is performed in one facility.

According to the disclosure, the device for the production of a moldhaving a fiber-reinforced support and at least two add-on piecesfeaturing synthetic material connected therewith has at least two toolcomponents. At least one tool component is movable relative to theother. Both tool components have a respective pressing surface, betweenwhich a fiber-reinforced mat can be inserted. When the device is in anopened state, a fiber-reinforced mat can be inserted. The toolcomponents are provided as mold halves and, when closed, provide the matwith a three-dimensional contour, molding and strengthening the mat bymeans of pressure. In one of the two tool components, referred to hereas a second tool component, at least one nozzle is provided, throughwhich liquid synthetic material can be pressed into the inserted mat insuch a fashion that the pressurized melt, which may be hot, penetratesthe molded or not-yet-molded mat and reaches at least one cavity awayfrom the nozzle on the opposite side. The at least one cavity away fromthe nozzle is provided in the other tool component, referred to here asa first tool component. Furthermore, at least one cavity at the nozzleis provided in the second tool component, which at least partiallyoverlaps with the cavity away from the nozzle in a cross sectionperpendicular to the inserted mat and therefore forms an overlappingarea.

After the cavity away from the nozzle has been filled with the liquefiedsynthetic material and melt continues to be injected, the injected meltpenetrates the mat in the overlapping area of both cavities and back up,filling the cavity at the nozzle. A special nozzle is not required forfilling the cavity at the nozzle in the first tool component.Furthermore, it is possible to first fill the cavity at the nozzle withthe synthetic material melt. After the cavity at the nozzle is filled,the synthetic material melt penetrates the mat in the overlapping areaand fill the cavity away from the nozzle. In some embodiments, the firsttool component does not have a nozzle, as long as there is at least onecavity at the nozzle and one cavity away from the nozzle, which can bothbe filled with synthetic material by one nozzle. The mat does notnecessarily have to be attenuated separately because this is doneautomatically by the pressurized melt. The cavity at the nozzle and thecavity away from the nozzle correspond to the form of one or a pluralityof add-on pieces, such as function elements. Examples of the functionelements may include a stiffening rib or a fastening part. The meltquantity and the pressure can be controlled by means of a controllablenozzle. Compared to a method of molding the support and later onattaching function elements, the number of tools and productionfacilities, and therefore the production costs are reduced. Compared toan injection-molded support with function elements, the weight isreduced.

The synthetic material structure, which is formed by the respectivecavity, can be an add-on piece or a plurality of add-on pieces, whichmay be determined by the intended functionality of the syntheticpart(s). The synthetic material melt can be injected through the molded,partially molded, or unmolded mat.

The fastening and/or integration of the add-on piece and the support areclearly improved because the injected synthetic material forms a bondwith the polymer of the mat, which may be heated. Furthermore, amechanical connection, such as a mechanical clawing, is created alongthe entire thickness of the injected area of the mat, which alsoimproves the integration. There will be no shoulders, bumps or the likeon the surface of the decorative side. By specifically injecting thesynthetic material through the fiber mat, the fiber mat still has vacuumin the surrounding areas for a potential subsequent laminating process.

According to the invention, only one feed orifice is needed to fill thecavity away from the nozzle and the cavity at the nozzle. This allowsfor additional design freedom of the add-on pieces at little additionalproduction effort and little modification of the device. Additionally,the mat does not have to be opened/cleared first at the transitionbetween the two cavities in a separate process step because this is doneautomatically by the pressurized melt during the injection moldingprocess. An additional advantage is the improved adhesion of the add-onelements because they are directly connected to one another.

In some embodiments, the cavity that is arranged in the direction offlow of the liquefied synthetic material after the overlapping area hasa greater dimension in directions perpendicular to the pressing surfacethan at least one dimension in a direction parallel to the pressingsurface in the same area. Because the synthetic material is introducedinto the cavities under a high pressure, at least part of the mat may bepressed into the cavity. Especially in the overlapping area, theliquefied synthetic material introduced under high pressure may notpenetrate the mat but rather press the mat as such into the cavity. Thismay limit a filling of the cavities with the synthetic material. Becausethe dimensions of the cavity that is arranged in the direction of flowof the liquefied synthetic material after the overlapping area has agreater dimension in the direction perpendicular to the pressing surfacethan at least one dimension in the directions parallel to the pressingsurface, only a part of the fiber material may penetrate the cavity dueto the inherent stiffness of the mat, and hence the risk of pressing themat into a cavity is reduced. At the same time, the special designensures that the liquefied synthetic material can build up sufficientpressure on the mat in the overlapping area so that the syntheticmaterial can simply penetrate the mat.

In some embodiments, the cavity that is arranged in the direction offlow of the liquefied synthetic material after the overlapping area hasa dimension of at least about 5 millimeters in the directionperpendicular to the pressing surface in the penetration area, and adimension of about 2 to about 3 millimeters in the direction parallel tothe pressing surface.

In some embodiments, the pressing surface of the first and/or the secondtool component has bumps in a peripheral area of the cavities. The bumpspenetrate the mat during the pressing process so that the fiber mat ismolded stronger in these areas and therefore compressed more than in thesurrounding areas. Because of the enhanced compressing, the fiber mat isless penetrable for the synthetic material being introduced into thecavities. This ensures that the synthetic material penetrates into thecavities only at the intended places and that there is no over-injectioninto the fiber mat. In some embodiments, the bumps are provided as websor lips, which run perpendicularly away from the pressing surface. Insome embodiments, the bumps have a height of about 5 to about 10 mm.

To remove the produced fiber-reinforced support part from the device,the first tool component has an ejector. The ejector can be provided asa retractable cylinder, for example. Because only the second toolcomponent has a nozzle, the production effort for the tool components issignificantly less than for conventional tool components because thenozzle and the ejector are split between the two tool components andtherefore the complexity of the individual tool components can bereduced.

In some embodiments, the fiber-reinforced support has a thickness ofabout 1 to about 3 millimeters, such as about 1.5 to about 2millimeters. Therefore, a support can be provided which has sufficientinherent stiffness as well as a low dead weight. Furthermore, it isensured that the liquid synthetic material sufficiently penetrates thefiber-reinforced support and that at the same time the supportrepresents a stable base for the add-on pieces to be generated.

In some embodiments, the nozzle is arranged in the second tool componentin the cavity at the nozzle so that the liquefied synthetic material,when it leaves the nozzle, immediately penetrates into the cavity at thenozzle, and penetrates the mat only after the cavity at the nozzle hasbeen filled. Because the cavity at the nozzle is filled directly by thenozzle, the synthetic material has to penetrate the mat only once tofill both cavities. Therefore, the liquefied synthetic material can beintroduced into the cavities with less pressure, which further reducesthe risk of over-injecting the liquefied synthetic material into themat.

Alternately, the nozzle in the second tool component can also bearranged outside of the cavity at the nozzle. In that case, theliquefied synthetic material, after it leaves the nozzle, is firstconveyed through the mat into the cavity away from the nozzle. After thecavity away from the nozzle is filled, the liquefied synthetic materialpenetrates the mat a second time in the overlapping area of the cavityaway from the nozzle and the cavity at the nozzle, and fills the cavityat the nozzle. Because residual synthetic material remains within themat as the synthetic material penetrates the mat to fill the cavities,repeated penetration of the liquefied synthetic material through the matcan create add-on pieces after solidification which have an especiallyfirm connection to the fiber-reinforced support without having to useadhesives or other bonding agents for this purpose.

In some embodiments, the mat is preheated, for example to a temperaturebetween about 100° C. and about 300° C., such as between about 180° C.and about 220° C., either outside of the tool or in the tool by means ofan integrated heating device. This simplifies the forming of athree-dimensional contour and, if applicable, the bonding with thesynthetic material to be injected. The heated mat is positioned betweenthe open tool components and fixed in position, if applicable. Fixationcan be achieved by means of a frame, clamps, or pins, etc.

In some embodiments, the device has at least one cutting edge where acontour cut or the cutting of a breakthrough is performed. The cuttingedge can be provided so that there is a cut at the cutting edge, forexample, immediately when the tool components are pressed together.Alternatively, the cutting edge can be designed such that the fiber matis pressed with a cutting contour at the cutting edge for a subsequentcutting of the support.

In some embodiments, the at east one nozzle is a hot nozzle with needleshutoff, through which the synthetic material is pressed onto the mat bymeans of pressure. With needle shutoffs, the nozzle opening is closedafter the injection by means of a needle. For example, the needle can bedesigned with a sharp tip, conically or cylindrically. The injectionresidue is pressed into the synthetic material part so that the needlesystem provides the surface of the add-on piece with a clean “seal” anda spotless geometry. Furthermore, one or a plurality of controllableneedle shutoffs can control the melt quantity and the melt pressure.

In some embodiments, the needle of the nozzle penetrates the mat, whichfacilitates the injection.

In some embodiments, the first tool component, i.e., the tool componenthaving the cavity on the side away from the nozzle, is movable whereasthe second tool component, i.e., the tool component having the nozzle,is stationary. Providing and supplying the synthetic material can bemanaged in a simple manner by the stationary tool component.

In some embodiments, the second and/or first tool component is providedwith a plurality, for example two or four, pressing surfaces ondifferent sides. In this way, different pressing patterns can berealized in a module-like fashion. Furthermore, the additional pressingsurfaces can interact with the corresponding pressing surfaces ofadditional tool components so that several mats can be worked on at thesame time. To that end, one of the tool components, which is alsoreferred to as a center tool component here, can be designed as a mobileturning unit so that the inserting of the fiber-reinforced mats and theremoval of the injected mats is realized by rotating the center toolcomponents.

In some embodiments, the center tool component interacts with two othertool components, for example at the same time, in such a fashion thattwo mats can be molded simultaneously and provided with add-on pieces,as long as there is at least one cavity at the nozzle and one cavityaway from the nozzle, both of which are filled with synthetic materialfrom only one nozzle.

The center tool component can be provided in a stationary and/or movablefashion. The two other tool components are designed such, for example,that both are movable, or one of the two tool components is stationaryand the other of the two tool components is movable.

As already indicated, the center tool component may be designed as amobile turning unit. The turning unit can be rotated relative to the twoother tool components.

If a center tool component is provided, a single-step or a two-stepprocess can be realized with the device:

In the single-step process, molds are provided at both sides of thecenter tool component, for example at the same time, according to theaforementioned process. This means that the output of the device isdoubled. In that case, the center tool component can be developed as astationary and/or movable tool component, as well as in form of aturning unit, for example to simplify the insertion of one or both matsto be molded in the one tool.

In the two-step process, the injection of the mat and the integration ofa first add-on piece or a first group of add-on pieces occur at one sideof the device. To that end, the tool is closed and the process isperformed similarly to the description above. Then the tool is openedand the turning unit with the intermediate product attached to it isrotated so that the intermediate product is delivered to a third toolcomponent. The tool is closed again to apply a decorative layer and/orto inject behind the mold and/or to integrate an additional group ofadd-on pieces with the mat in an injection molding process. Bydelivering the mats to the device in such a fashion that both moldcavities are provided with mats in each closing process, an extension ofthe production cycle can be avoided despite the two-step process.

Together, the three tool components constitute two units for molding themats and integrating add-on pieces. In some embodiments, at least thecenter tool component and one of the two tool components are provided ina movable fashion, with the two outer tool components, and thereforealso the outer movable tool component, each having a nozzle. In someembodiments, the center tool component has on both sides at least onerespective cavity away from the nozzle and no nozzle, with the othertool components having at least one nozzle and a cavity at the nozzle.

In some embodiments, the molding of the synthetic material, e.g., theproduction of the add-on pieces, is performed immediately after theclosing of the tool and the injection of the mat are completed. In thisway, it can be ensured that the degree of hardening of the fiber mat isstill optimally low so that it may be guaranteed that the syntheticmaterial can penetrate the fiber mat. To that end, the fiber mat has athermoplastic matrix, in particular made of synthetic material. Thematrix can include PP, ABS, PC/ABS, or PA, and can have filler-and/orreinforcement materials. Furthermore, the fiber mat is sufficientlyheated prior to the pressing process so that the melting temperature ofthe thermoplastic matrix is exceeded and it melts open. Thethermoplastic matrix guarantees that the fiber-reinforced support partgenerated from the fiber mat retains its form even after the pressingprocess and simultaneously allows an injection through the mat duringthe pressing process.

In some embodiments, the synthetic material is introduced into thecavities while the thermoplastic matrix is melted open.

Therefore, this facilitates a penetration of the synthetic materialthrough the fiber mat even further and no over-injections would becreated. In some embodiments, the thermoplastic matrix of the mat andthe liquefied synthetic material include the same synthetic material.Using the same synthetic material guarantees a firm bonding connectionbetween the add-on pieces and the fiber-reinforced support.

Because the synthetic material may need to penetrate the fiber matmultiple times to fill all cavities, the synthetic material may beintroduced into the cavities of the tool components at a pressure ofabout 30,000 kPa to about 50,000 kPa, to ensure a complete filling ofall cavities.

In some embodiments, the synthetic material includes a polymer, such asPP, ABS, PC/ABS, or PA. In some embodiments, the polymer may includeadded filler-and/or reinforcing materials, such as PP T20.

In some embodiments, the mat is a thermo- or duroplastic fiber systemwith natural fibers, glass fibers, mineral fibers, synthetic fibers,cellulose fibers, and/or carbon fibers, and has a thickness of about 8to about 15 millimeters prior to injection.

The disclosure has been explained for use in an automobile.Nevertheless, the disclosure can also be implemented in other areas,such as in the transportation area, especially in air and sea travel,furniture making, etc. The disclosure is particularly suitable for theinterior of motor vehicles because this requires, to a high degree, anappealing appearance over a long service life at a high productionproductivity. Furthermore, additional advantages and characteristics ofthe disclosure are shown in the following description of embodiments.The characteristics described there can be implemented on their own orin combination with one or a plurality of the characteristics mentionedabove to the extent that the characteristics are not contradictory. Thefollowing description of the embodiments makes reference to theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic view of a device for producing a mold with twotool components in an opened state.

FIG. 1B shows the device in FIG. 1A in a closed state.

FIG. 2A shows a device for the production of a mold with three toolcomponents in an opened insertion state.

FIG. 2B shows the device in FIG. 2A in a dosed state.

FIG. 3 shows a device for the production of a mold with three toolcomponents in an opened state.

FIG. 4 shows an additional device for the production of a mold in anopened state.

DESCRIPTION OF THE EMBODIMENTS

FIG. 1A shows an exemplary device (also referred to as a “tool”)consistent with embodiments of the disclosure, including a movable firsttool component 10 and a stationary second tool component 20. The twotool components 10, 20 are developed as molds with pressing surfaces 11and 21. When a fiber mat 30 is inserted between the pressing surfaces 11and 21 and the pressing surfaces 11 and 21 are pressed together, thefiber mat 30 can have the form of a desired support element. FIG. 1Ashows an opened state, when the fiber mat 30 is being inserted.

The stationary tool component 20 has a hot nozzle 22 with a needleshutoff, which is suitable for injecting a hot synthetic material meltagainst the still unmolded or already molded mat 30 by means ofpressure. If it is pressed against the still unmolded mat 30, the toolhas at least one additional intermediate state in which the tool isclosed, but a molding of the mat does not yet occur, or occurs onlypartially.

When the device is closed, the nozzle 22 is located opposite a cavity 12away from the nozzle so that, when the needle of the shutoff of thenozzle 22 is opened, the hot, pressurized melt penetrates the molded orat least partially molded mat 30 and reaches the opposite cavity 12 awayfrom the nozzle. In this way, an add-on piece is created on a side ofthe mat 30, which is also referred to as a rear side. The hollow spaceof the cavity 12 away from the nozzle corresponds to the form of theadd-on piece. The cavity 12 away from the nozzle can be provided in aninterchangeable or movable tool element 13 so that with a simpleconversion of the tool, various add-on pieces and therefore variousdecorative element supports or decorative elements can be produced.

In the second tool component 20, a cavity 24 at the nozzle is provided.If additional synthetic material is injected after the cavity 12 awayfrom the nozzle has been filled, the synthetic material will penetratethe mat 30 again and reach the cavity 24 at the nozzle.

Consistent with embodiments of the disclosure, when producing a mold,the mat 30 is placed between the tool components 10 and 20, and, ifapplicable, fastened at one of the two tool components 10 and 20. Thetemperature of the mat 30 can be increased in advance or with a heatingdevice that is integrated into one or both of the tool components 10,20. The tool components 10, 20 move together and press the mat 30, asshown in FIG. 1B.

The molding strengthens the mat 30 and determines the three-dimensionalcontour of the support to be developed. Cooling the molded mat 30 leadsto a dimensionally stable support. Furthermore, as the two toolcomponents 10 and 20 close, a cutting edge 23 acts on the mat 30,creating a contour or a breakthrough on the mat 30.

During or after completion of the molding process, a synthetic materialmelt is introduced into the closed tool via the nozzle 22, whichpenetrates the fiber mat 30 and fills the cavity 12 away from thenozzle. To simplify the penetration of the synthetic material melt, thefiber mat 30 can be first perforated or provided with holes, or renderedpermeable in another way. For example, the needle of the nozzle 22 canbe driven to reach out of the nozzle 22 and into the mat 30 to shortenthe penetration path or create a breakthrough through the mat 30.

If excessive melt is supplied, the melt will penetrate the mat 30 againand fill the cavity 24 at the nozzle. The mat 30 does not have to beseparately attenuated between the two cavities 12 and 24 because this isdone automatically by the pressurized melt. By means of the controllableneedle-shutoff nozzle 22, the melt quantity and the pressure can becontrolled. Furthermore, the needle system provides the surface with aclean finish to obtain a bump-free geometry, if applicable. After thecooling time, the movable tool component 10 opens. The final molding ofthe component is done by means of ejection or slanted ejection.

In some embodiments, penetration of the mat 30 during reflux isfacilitated by overlapping the cavities 12 and 24 at least partially incross-section (perpendicular to the inserted mat 30). This is shown inthe figures in that the cavity 12 away from the nozzle has a section 14that is provided so that it partially overlaps with the cavity 24 at thenozzle. In that case, the melt does not have to penetrate the mat 30 andalong the extension of the mat 30 up to the cavity 24 at the nozzle, butrather first flows into the section 14 and then penetrates the mat 30 inthe shortest way, i.e., in a direction perpendicular to the orientationof the mat 30. Accordingly, the pressure for injecting the melt can bereduced. The mat 30 is penetrated gently, i.e., there is little damageto a fiber structure of the mat 30.

As the injected synthetic matter penetrates the thermo- or duroplasticfiber mat system, a firm connection is created, which is based not onlyon a mechanical rear-clawing of the solidified add-on piece and thedimensionally stable support, but also on a material connection of therespective synthetic materials because both are still in a viscous,connectable state during the production process. After the product hascooled, an excellent integrity of the add-on pieces and thefiber-reinforced support is achieved.

In some embodiments, additional process steps, such as, for example,cutting, end-molding, laminating, and the like can be performed.

FIGS. 2A and 2B show another exemplary device consistent withembodiments of the disclosure. In the device shown in FIG. 2A and 2B,the tool component 20 is designed as a turning unit 26, which has twotool sides 25 for pressing and injecting. The two tool sides 25 eachhave a pressing surface 21 and 21′, which can be identical to ordifferent from each other. The pressing surfaces 21 and 21′ interactwith the pressing surface 11 of the tool component 10 and a pressingsurface 41 of a third tool component 40. The turning unit 26 isrotatable relative to the tool components 10 and 40.

With the device shown in FIGS. 2A and 2B, a one-step process and atwo-step process can be performed.

The one-step process is similar to the production process describedabove in regard to the device shown in FIGS. 1A and 1B, with the deviceof FIGS. 2A and 2B allowing a simultaneous production of two molds. Thetool component 10 has the cavity 24 at the nozzle. Alternately or inaddition, the tool component 40 may have a cavity at the nozzle (notshown in the figures). Consistent with embodiments of the disclosure,that the turning unit 26 is able to rotate simplifies the insertion ofthe mats. After two mats 30 and 30′ have been inserted when the deviceis in the state shown in FIG. 2A, the turning unit 26 rotates, forexample, clockwise by 90°, such that the pressing surfaces 21 and 21′ ofthe tool sides 25 are opposite the corresponding pressing surfaces 11and 41 of the tool components 10 and 40. By moving together, aninjection is performed on both sides, as shown in FIG. 2B, which createsthe fiber-reinforced supports. At the same time, or after the pressing,if applicable after a brief waiting time, the synthetic material isinjected through the nozzles 22 and 42 into the appropriate cavities 12,24, and 12′. After the cooling time is over, the tool opens and theturning unit rotates again, for example, clockwise by 90° orcounter-clockwise by 90°, and then the two produced molds can beremoved.

In the two-step process, a mat 30′ is first inserted and/or chucked atthe one side of the turning unit 26, similar to an insertion state asthe one shown in FIG. 2A, whereas at the other side, a mat 30 that hasalready been molded and provided with add-on pieces rests at thepressing surface 21 of the turning unit 26. Then, the turning unit 26 isrotated according to FIG. 3 so that the newly inserted mat 30′ interactswith the third tool component 40 when the tool is closed, whereas thesecond mat 30 interacts with a first tool component 50 when the tool isclosed. The newly inserted mat 30′ is molded and at least one add-onpiece is injection-molded similar to the process shown in FIG. 1B, withthe cavity 44 at the nozzle being provided in the tool component 40here. The already molded mat 30 is laminated with a decorative layer 60,preferably a decorative foil. To that end, the pressing surface 51 ofthe first tool component 50 interacts with the turning unit 26 in asuitable fashion.

In this way, a mat runs through two molding stages and/or twointegration stages. It is possible to break down the two process stepsof injection and integration to the two sides of the device. In thatcase, the tool component 50 or 40 and one of the two sides 25 can befree of cavities and/or nozzles.

The remaining process steps of molding and integrating an add-on pieceare similar to the above description with respect to FIGS. 1A and 1B.

FIG. 4 shows another exemplary device consistent with embodiments of thedisclosure, where a movable first tool component 10 and a stationarysecond tool component 20 are arranged oppositely. Both tool components10, 20 have a pressing surface 11, 21; the first tool component 10 andits pressing surface 11 can be driven into the pressing surface 21 ofthe second tool component in such a fashion that a fiber mat 30 insertedbetween the tool components 10, 20 can be pressed and molded between thepressing surfaces 11, 21. The second tool component 20 includes a cavity24 at the nozzle. Furthermore, a nozzle 22 is arranged in the secondtool component to introduce liquefied synthetic material. The nozzle 22runs directly into the cavity 24 at the nozzle. The first tool component10 includes two cavities 12, 43 away from the nozzle, which arespatially separated. The cavity 24 at the nozzle as well as the cavities12, 43 away from the nozzle include sections 14, 44, 45, 46, whichensure an overlapping of the cavities 12, 43 away from the nozzle andthe cavity 24 at the nozzle so that the cavity 24 at the nozzle forms arespective overlapping area 47, 48 with the two cavities 12, 43 awayfrom the nozzle.

In a process (not shown) for developing the add-on pieces, a preheatedfiber mat 30 is arranged between the two tool components 10, 20 and thenthe first tool component 10 is moved into the second tool component 20in such a fashion that the fiber mat 30 is molded between the pressingsurfaces 11, 21 of the tool components 10, 20. Immediately after thefirst tool component 10 has completed its movement into the second toolcomponent 20, liquefied synthetic material is filled into the cavity 24at the nozzle via the nozzle 22. Even after the cavity 24 at the nozzlehas been filled with synthetic material, additional synthetic materialis introduced into the cavity 24 at the nozzle via the nozzle 22 so thatthe pressure of the synthetic material on the fiber mat 30 increases, inparticular in the overlapping areas 47, 48. As soon as sufficientpressure has been built up, the synthetic material penetrates the fibermat 30 in the overlapping areas 47, 48 and flows into the cavities 12,43 away from the nozzle to fill them. The subsequent hardening of theliquid synthetic material then forms the add-on pieces.

Other embodiments of the disclosure will be apparent to those skilled inthe art from consideration of the specification and practice of theinvention disclosed herein. It is intended that the specification andexamples be considered as exemplary only, with a true scope and spiritof the invention being indicated by the following claims.

1. (canceled)
 2. A device for producing a molded part using a firstmaterial, comprising: a first tool component comprising: a firstpressing surface extending in a first direction; and a first cavityhaving an extending section that is an extension of the first cavity andextends in the first direction; and a second tool component having: asecond pressing surface complementary to the first pressing surface; anozzle configured to supply a molding material; and a second cavity;wherein: the first tool component is movable towards the second toolcomponent in a second direction to form a closed position, the seconddirection being perpendicular to the first direction; the extendingsection extends the first cavity towards the second cavity in the closedposition, such that only the extending section overlaps a portion of thesecond cavity with respect to a cross-section perpendicular to the firstand second pressing surfaces; and the extending section is configured toallow, when the first and second pressing surfaces face each other inthe closed position, the molding material to flow substantially parallelto the first material in the first direction, the first material beinginserted between the first and second tool components.
 3. The deviceaccording to claim 2, wherein, when the first and second pressingsurfaces face each other in the closed position, the nozzle isconfigured to supply the molding material such that: the moldingmaterial penetrates the first material a first time to fill the firstcavity, including the extending section, wherein the first material ispositioned between the first and second pressing surfaces, and themolding material penetrates the first material during a second time, inthe overlapping area, to fill the second cavity after the first cavity,including the extending section, is filled.
 4. The device according toclaim 2, wherein, when the first and second pressing surfaces face eachother in the closed position, the extending section is configured toallow the molding material to flow, in the overlapping area, from theextending section to the second cavity after the first cavity, includingthe extending section, is filled.
 5. The device according to claim 2,wherein at least a portion of the first cavity is larger in a firstdimension perpendicular to the first pressing surface than in a seconddimension parallel to the first pressing surface.
 6. The deviceaccording to claim 5, wherein the first dimension is at least about 5mm.
 7. The device according to claim 5, wherein the second dimension isabout 2 to about 3 mm.
 8. The device according to claim 2, wherein: atleast one of the first and second pressing surfaces has bumps, the bumpson the first pressing surface are provided in a peripheral areasurrounding the first cavity, and the bumps on the second pressingsurface are provided in a peripheral area surrounding the second cavity.9. The device according to claim 2, wherein the nozzle is arrangedinside the second cavity.
 10. The device according to claim 2, whereinthe nozzle is arranged outside the second cavity.
 11. The deviceaccording to claim 2, further comprising: at least one cutting edgeconfigured to create a contour or a breakthrough on the first material.12. The device according to claim 2, wherein the nozzle is a hot nozzlewith a needle, configured to press a material through the nozzle bypressure.
 13. The device according to claim 12, wherein the needle isconfigured to reach out of the nozzle.
 14. The method according to claim2, wherein the molding material is a liquefied polymer comprising atleast one of PP, ABS, PC/ABS, or PA.
 15. The method according to claim14, wherein the liquefied polymer has at least one of a filler or areinforcing substance.
 16. The method according to claim 12, wherein thefirst material is a fiber-reinforced mat.
 17. An apparatus for producinga molded part, comprising: a first tool component having: a firstpressing surface extending in a first direction; and a first cavityhaving an extending section that is an extension of the first cavity andextends in the first direction; and a second tool component having: asecond pressing surface complementary to the first pressing surface; anozzle configured to supply a molding material; and a second cavity,wherein: at least one of the first and second tool components isconfigured to be movable relative to the other in a closed position; andwhen the first and second pressing surfaces face each other in theclosed position: the extending section extends the first cavity towardsthe second cavity such that only the extending section overlaps aportion of the second cavity with respect to a cross-sectionperpendicular to the first and second pressing surfaces; and theextending section is configured to allow the molding material to flowalong the first direction, in the overlapping area, from the extendingsection and, after the first cavity including the extending section isfilled, to the second cavity.
 18. The apparatus according to claim 17,wherein at least a portion of the first cavity is larger in a firstdimension perpendicular to the first pressing surface than in a seconddimension parallel to the first pressing surface.
 19. The apparatusaccording to claim 17, wherein: at least one of the first and secondpressing surfaces has bumps, the bumps on the first pressing surface areprovided in a peripheral area surrounding the first cavity, and thebumps on the second pressing surface are provided in a peripheral areasurrounding the second cavity.
 20. The apparatus according to claim 17,wherein: a fiber-reinforced mat is inserted between the first and secondpressing surfaces; and when the first and second pressing surfaces faceeach other in the closed position, the nozzle is configured to supplythe molding material such that: the molding material penetrates the mata first time to fill the first cavity, including the extending section,and the molding material penetrates the mat during a second time, in theoverlapping area, to fill the second cavity after the first cavity,including the extending section, is filled.
 21. The apparatus accordingto claim 17, wherein: at least one of the first and second pressingsurfaces has bumps, the bumps on the first pressing surface are providedin a peripheral area surrounding the first cavity, and the bumps on thesecond pressing surface are provided in a peripheral area surroundingthe second cavity.